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Case Study 2 - Aluminum Truck Bodies Lean Deployment

Client: Manufacturer of aluminum truck bodies for the retail and home delivery markets

Challenge: Improve the operating efficiencies of the manufacturing operation and reduce manufacturing issues generated by the fabrication shop

Our Role: Develop, oversee and lead implementation of a lean manufacturing system while minimizing expenditures during the plant's slow period.

Implementation Strategy:
1. Deploy 5S in a single focused area to demonstrate potential results
2. Deploy 5S in the multiple plant areas to establish a lean foundation
3. Identify bottleneck operations and machinery downtime issues
4. Train salary and hourly team members in lean techniques on a Just-In-Time basis

Results achieved:
1. Fab shop tools updated / systems revised with $300K in annual savings
2. Productivity improvements resulting in $100K in annual improvements
3. Built a self-sustaining team
4. Identified and resolved many maintenance issues prior to actual downtime being incurred

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